Thermal insulating container

ABSTRACT

A thermal insulating transport container comprising an inner lining, wherein the inner lining is fabricated from a thermal insulation sheet material; and an outer box layer, wherein the outer box layer is fabricated from a water resistant thermal insulation sheet material, wherein a side wall of the outer thermal insulation box layer is connected to an adjacent side wall of the outer thermal insulation box layer by at least one locking tab.

TECHNICAL FIELD

The present invention relates to a thermal insulating transport container. More particularly, the present invention relates to a thermal insulating transport container for transportation of temperature sensitive items, such as seafood, out of cold chain.

BACKGROUND ART

Known packaging for the storage and transportation of temperature sensitive items, such as seafood, includes expanded polystyrene (Styrofoam) boxes and polyethylene coated or wax impregnated corrugated fibreboard boxes which are packed with a chilling material, such as ice, to keep the items chilled whilst out of the cold chain storage and delivery within the recommended temperature range (which for seafood is usually 2° C. to 8° C.).

The disadvantage of using expanded polystyrene boxes is that they have a limited lifespan due to disintegration of the box during use. In addition, expanded polystyrene poses an environmental hazard as polystyrene can break down into small pieces which are not appreciably biodegradable. Additionally, this type of packaging material tends to have poor barrier properties and consequently may be subject to contamination by its contents. In addition, they typically require a single use plastic liner bag which is environmentally unsustainable.

In addition, the efficiency of use is limited as the boxes have fixed dimensions and can be bulky to transport and store when not in use as they are not collapsible. Further due to the fixed dimensions their usability is limited for items of non-standard size especially when it is not possible to break items up to fit the container (for food

Many countries around the world are banning polystyrene in the food and grocery sector—including America and Hong Kong, which are Australia's large seafood trading partners. Airlines are reviewing expanded polystyrene air freight approval status due to the number of product spills requiring cleaning and inspection of the plane.

Thus, there would be an advantage if it were possible to provide an improved thermal insulating container or at least one that ameliorates the aforementioned problems.

It will be clearly understood that, if a prior art publication is referred to herein; this reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country.

SUMMARY OF INVENTION

The present invention is directed to an improved thermal insulating container which may at least partially overcome at least one of the aforementioned disadvantages or provide the consumer with a useful or commercial advantage.

With the foregoing in view, the present invention relates to a thermal insulating container for use in containing and transporting temperature sensitive goods, such as seafood. The present invention provides the ability to deliver temperature sensitive goods “out of cold chain” through a sustainable means whilst maintaining the quality of the product. The thermal insulating container of the present invention provides an alternative to polystyrene in a reusable sustainable format.

With the foregoing in view, the present invention in one form, resides broadly in a thermal insulating transport container comprising:

-   -   an inner lining, wherein the inner lining is fabricated from a         thermal insulation sheet material; and     -   an outer box layer, wherein the outer box layer is fabricated         from a water resistant thermal insulation sheet material,         wherein a side wall of the outer box layer is connected to an         adjacent side wall of the outer box layer by at least one         locking tab.

The thermal insulating transport container may be used for any suitable purpose. In an embodiment of the invention, the thermal insulating transport container may be used to transport perishable goods. It will be understood that the term “perishable” used throughout this specification refers to goods whose efficacy, freshness, value, safety to consumers and so on is temperature sensitive, time sensitive, or a combination of the two.

For instance, perishable goods may include meat and meat by-products, fish and seafood, dairy products, fruits and vegetables, flowers, pharmaceutical products, chemicals, organs for transplant and the like. Preferably, the thermal insulating transport container may be used to transport temperature sensitive goods. However, it is envisaged, that in use, the thermal insulating transport container may be used to transport any form of goods wherein transport and environmental conditions may have adverse effects on the quality, safety, appearance, shelf-life, or the like, of the goods over time.

The thermal insulating transport container may be used to transport perishable goods by land, air, train, or ship. However, it will be understood that the type of transport may vary depending on a number of factors, such as the goods to be transported, whether a refrigerated container is required for transport and the destination of the goods.

The thermal insulating transport container may be of any suitable size, shape or configuration. Preferably, the size and shape of the thermal insulating transport container is determined at least in part by the type of perishable goods to be transported. For instance, if a large whole fish (or more than one fish) is to be transported then a larger thermal insulating transport container may be required than when fish fillets are being transported. However, it will be understood that size, shape and configuration of the thermal insulating transport container may vary depending on a number of factors, such as commercial considerations, transport type and destination and whether the perishable goods are live, fresh, chilled, or frozen.

The thermal insulating transport container comprises an inner lining. The inner lining may be fabricated from any suitable type of material having thermal insulation properties. Preferably, the inner lining may be fabricated from a sheet material. Preferably, the inner lining may be fabricated from a flexible sheet material. In an embodiment of the invention, the inner lining may be fabricated from a thermal insulation sheet material. Any suitable thermal insulation sheet material may be used. However, it is envisaged that in use, the thermal insulation sheet material may reflect radiant heat, thereby reducing or minimising temperature increases for objects at least partially surrounded by the thermal insulation sheet material. Preferably, the thermal insulation sheet material reflects a substantial portion of radiant heat. In some embodiments of the invention, the thermal insulation sheet material may reflect at least 50% of radiant heat. More preferably, the thermal insulation sheet material may reflect at least 75% of radiant heat. Most preferably, the thermal insulation sheet material may reflect at least 95% of radiant heat. In a preferred embodiment of the invention, the thermal insulation sheet material reflects at least 87% of radiant heat.

The thermal insulation sheet material may comprise at least one layer. In an embodiment of the invention, the thermal insulation sheet material may be a multi-layer structure. In an embodiment of the invention, the thermal insulation sheet material comprises an insulation layer located between at least one upper layer and at least one lower layer. Preferably, the insulation layer may be encapsulated between at least one upper layer and at least one lower layer, such that the insulation layer may be substantially enclosed by at least one upper layer and at least one lower layer. The insulation layer may be fabricated from any suitable material. For instance, the insulation layer may be fabricated from an extruded polymer, an expanded polymer, a foamed polymer, or combinations thereof. Thus, the insulation layer may be fabricated from a polymer (and especially a foamed polymer) such as, but not limited to, polyethylene, ethylene vinyl acetate, ethylene propylene diene terpolymer, neoprene, nitrile, polyvinyl chloride, silicone, fluroelastomer, urethane or the like, or any suitable combination thereof. The insulation layer may be fabricated from a closed cell foam insulation material or an open cell foam insulation material. In a preferred embodiment of the invention, the insulation layer may comprise a closed cell foam material. A closed cell foam material has an open cell content of 20% or less, 10% or less, 5% or less, and can have zero percent open cell content. In a preferred embodiment, the insulation layer may be a closed cell polyethylene foam core.

The upper and lower layers may be fabricated from any suitable material. Preferably, the upper and lower layers may be provided with resistance to one or more environmental factors. Preferably, the upper and lower layers may be antimicrobial, reflective, thermally insulated, water-resistant, waterproof, UV-resistant, chemical resistant, impact resistant, fire resistant, or a combination thereof.

Preferably, the thermal insulation sheet material comprises at least one reflective layer. The reflective layer may be fabricated from any suitable material, including, but not limited to a metal foil (such as aluminium foil, aluminium foil laminates and so on), metallised plastic films, and the like. In an embodiment of the invention, the reflective layer may be a metallised polyethylene. Although the layers may be located in any suitable orientation, it is envisaged that a reflective layer may be placed in contact with, or close proximity to, the outer box layer. Thus, in this embodiment of the invention, the reflective layer forms an outer facing of the inner lining. In an alternative embodiment of the invention, a reflective layer forms an inner facing of the inner lining. In an embodiment of the invention, the thermal insulation sheet material comprises a foam layer encapsulated between two or more layers of a reflective material.

Preferably, the thermal insulation sheet material comprises at least one layer of an antimicrobial material. The antimicrobial layer may be fabricated from any suitable material, including but not limited to an antimicrobial polymer, silver nanoparticle-coated polymers, and the like. In an embodiment of the invention, the antimicrobial layer may be an antimicrobial polyethylene. Although the layers may be located in any suitable orientation, it is envisaged that an antimicrobial layer may be placed in contact with, or close proximity to, the perishable goods. Thus, in this embodiment of the invention, the antimicrobial layer forms an inner facing of the inner lining. In an alternative embodiment of the invention, an antimicrobial layer forms an outer facing of the inner lining. In an embodiment of the invention, the thermal insulation sheet material comprises a foam layer encapsulated between two or more layers of an antimicrobial material. Preferably, the antimicrobial material may be a food grade antimicrobial material.

In an embodiment of the invention, the thermal insulation sheet material comprises a foam layer encapsulated between one or more layers of a reflective material and one or more layers of an antimicrobial material.

Preferably, the inner lining may be fabricated from a flexible thermal insulation sheet material. The thermal insulation sheet material may be of any suitable thickness. However it will be understood that the thickness of the thermal insulation sheet may vary depending on a number of factors, such as the requirements of the perishable goods to be transported, the environment ambient temperatures and the degree of flexibility required of the sheet material.

Preferably, the inner lining may be assembled from a food grade approved thermal insulation sheet material. For the purposes of the specification, the term ‘food grade’ means the inner lining is permitted to come into contact with food for human or animal consumption.

In a preferred embodiment, the inner lining may be provided with resistance to one or more environmental factors. For instance, the inner lining may be water resistant, waterproof, UV-resistant, chemical resistant, impact resistant, fire resistant, or a combination thereof. In a preferred embodiment of the invention, the inner lining may be at least water resistant. Preferably, the inner lining may be substantially waterproof, such that if the cooling material melts or frozen goods defrost the resulting water does not leak out from the inner lining.

Any suitable means of providing the inner lining with water resistance may be used. For instance, the inner lining may be formed of a substantially water-resistant thermal insulation sheet material, may be provided with a water repellent coating, may be provided with a lining having a high moisture barrier, or assembled in such a way that the inner lining may be at least partially water tight or water resistant, or combinations thereof. Preferably, the thermal insulation sheet material may have sealed edges. In this way, the thermal insulating capacity of the material is improved and the sheet material has improved water-resistance. Any suitable technique to seal the edges of the sheet material may be used. However, it will be understood that the sealing technique may vary depending on a number of factors, such as the type of sheet material to be sealed, the thickness of the sheet material, and the degree of sealing required. For instance, the edges of the sheet material may be sealed by using an adhesive or adhesive tape, heat treatment, chemical treatment, mechanical treatment (such as ultrasonic welding, compression, and the like), or a combination thereof.

In an embodiment of the invention, at least a portion of the periphery of the sheet material may be sealed. In an alternative embodiment of the invention, substantially all of the periphery of the sheet material may be sealed. In an embodiment of the invention, at least a portion of the periphery of the sheet material may be sealed prior to assembling the sheet material into an inner lining. In an embodiment of the invention, at least a portion of the periphery of the inner lining may be sealed after assembly from a sheet material.

The inner lining may be of any suitable size, shape, or configuration. Preferably, however, the inner lining is of sufficient size and shape to fit within the internal dimensions of the outer box layer. In an embodiment of the invention, the inner lining may be adapted to be at least partially received and retained within the outer box layer. Preferably, substantially all of the inner lining may be received and retained within the outer box layer.

In an embodiment of the invention, the dimensions of the inner lining are less than the internal dimensions of the outer box layer such that only a portion of the inner lining may be retained in abutment with, or close proximity to, an inner surface of the outer box layer. In an alternative embodiment of the invention, the dimensions of the inner lining are substantially identical to the internal dimensions of the outer box layer such that substantially all of the inner lining may be retained in abutment with, or close proximity to, an inner surface of the outer box layer.

In an embodiment of the invention, the inner lining may be retained in proximity to, but not be attached to, an inner surface of the outer box layer. It is envisaged that, in use, an air gap formed between the inner lining and the outer box layer may create a thermal barrier between the inner lining and the outer box layer. The inner lining may be retained in proximity to an inner surface of the outer box layer by any suitable means. In an embodiment of the invention, an insulating material may be disposed between the inner lining and the outer box layer. In an alternative embodiment of the invention, the inner lining may be at least partially supported by at least one support member attached to an inner surface of the outer box layer, such that the at least one support member provides separation between the inner lining and an inner surface of the outer box layer. In a further embodiment of the invention, cooling material, such as ice or gel packs, may be disposed between the inner lining and the outer box layer.

In an alternative embodiment of the invention, the inner lining may be attached to at least one inner surface of the outer box layer. It is envisaged that in use, attaching the inner lining to at least one inner surface of the outer box layer may reduce movement of, and potential damage to, the contents of the thermal insulating transport container. The inner lining may be attached to an inner surface of the outer box layer by any suitable means. In an embodiment of the invention, the inner surface of the outer box layer may be attached to an inner surface of the outer box layer using an adhesive, an adhesive tape, an aluminium foil tape, or a mechanical fastener (such as stitches, staples), or any suitable combinations thereof.

The inner lining may be formed in any manner known in the art, e.g. by bending a sheet of material into a sleeve and longitudinally closing the sleeve by joining overlapping or abutting side edges of the sheet material to form a side wall. Alternatively, at least one side wall of the inner lining may be formed by folding a blank or stamped sheet material along preformed lines to produce the sleeve.

One or more sheets of material may be used to form the inner lining. In an embodiment of the invention, two or more sheets of material may be used to form the inner lining. The inner lining may have any suitable shape when viewed from above. For instance, the one or more side walls of the container may define a substantially circular, square, rectangular, hexagonal or octagonal void into which the perishable goods may be placed. In an embodiment of the invention, side walls of the inner lining may be formed by bending a flexible sheet of material along preformed lines and longitudinally closing the ends using an aluminium tape. Preferably, side walls of the inner lining may be formed by bending a flexible sheet of material along preformed lines and fastening adjacent side edges together.

Overlapping or abutting side edges of the sheet material may be fastened together using any suitable technique. However, it will be understood that the fastening technique may vary depending on a number of factors, such as the type of sheet material to be sealed, the thickness of the sheet material, and the degree of sealing required. For instance, the overlapping or abutting side edges of the sheet material may be fastened using an adhesive, an adhesive tape, an aluminium foil tape, a mechanical fastener (such as stitching, staples), heat treatment, chemical treatment, mechanical treatment (such as ultrasonic welding, compression, and the like), or any suitable combinations thereof. In an embodiment of the invention, adjacent side edges may be fastened together by thermally sealing. Alternatively, the edges of the sheet material may be fastened together by inserting one or more locking tabs located on the edge of a sheet material at least partially into one or more tab-retaining slots located on an opposing edge of a sheet material. It is envisaged, that in use, more than one technique for fastening the edges of a sheet material may be used. In an embodiment of the invention, overlapping or abutting side edges of the sheet material may be sealed with an adhesive water-proof tape. In this instance, it is envisaged that sealing abutting side edges of the inner lining with a water-proof tape may improve the water-resistance of the inner lining.

The thermal insulating transport container may be provided with a cooling material. Any suitable cooling material may be provided. Preferably, however, the type of cooling material which may be used is determined at least in part by the type of thermal insulating transport container and relevant transport and food regulations. Suitable cooling materials include dry ice, wet ice, gel coolants, ice gel packs, or a combination thereof. The cooling material may be located in any suitable portion of the thermal insulating transport container. For instance, the cooling material may be located in proximity to the perishable goods to be transported, between the inner lining and the outer box layer, or combinations thereof. It is envisaged that the location of the cooling material may depend upon the type of perishable goods to be transported.

The thermal insulating transport container comprises an outer box layer. The outer box layer may be of any suitable size, shape, or configuration. In an embodiment of the invention, the outer box layer may be substantially the same dimensions as the thermal insulating transport container. Preferably, the outer box layer is the outer layer of the thermal insulating transport container. The outer box layer may have any suitable shape when viewed from above. For instance, the one or more side walls of the container may define a substantially circular, square, rectangular, hexagonal or octagonal void into which the inner lining may be placed.

In an embodiment of the invention, the thermal insulating transport container comprises a lid. The lid may be of any suitable, size or configuration. Preferably, however, the lid is of sufficient size, shape and configuration to close the outer box layer.

The outer box layer and/or the lid may be fabricated from any suitable type of material with relatively high impact resistance and thermal insulation properties. For instance, the outer box layer and/or the lid may be fabricated from any suitable material, including but not limited to corrugated fibreboard, cardboard, biopolymers, polymers, semi-rigid plastics, and combinations thereof. In an embodiment of the invention, the outer box layer and/or the lid may be fabricated from a polypropylene material. In an embodiment of the invention, the outer box layer and the lid may be fabricated from the same type of material. In an alternative embodiment of the invention, the outer box layer and the lid may be fabricated from different types of materials.

In a preferred embodiment, the outer box layer and/or the lid may be provided with resistance to one or more environmental factors. For instance, the outer box layer and/or the lid may be water resistant, waterproof, UV-resistant, chemical resistant, impact resistant, fire resistant, or a combination thereof. In a preferred embodiment of the invention, the outer box layer and/or the lid may be at least water resistant. Preferably, the outer box layer may be substantially waterproof, such that if the cooling material melts or frozen goods defrost, the resulting water does not leak out from the outer box layer. Preferably the lid may be substantially waterproof, such that rain or water leaking from containers located above the thermal insulating transport container does not penetrate into the thermal insulating transport container.

Any suitable means of providing the outer box layer and/or the lid with water-resistance may be used. For instance, the outer box layer and/or the lid may be formed of a substantially water-resistant thermal insulation sheet material, may be provided with a water repellent coating, may be provided with a lining having a high moisture barrier, or assembled in such a way that the outer box layer and/or the lid may be at least partially water-tight or water-resistant, or combinations thereof. Preferably, the water-resistant thermal insulation sheet material may have sealed edges. In this way, the thermal insulating capacity of the material is improved and the sheet material has improved water-resistance. Any suitable technique to seal the edges of the sheet material may be used. However, it will be understood that the sealing technique may vary depending on a number of factors, such as the type of sheet material to be sealed, the thickness of the sheet material, and the degree of sealing required. For instance, the edges of the sheet material may be sealed by using an adhesive or adhesive tape, heat treatment, chemical treatment, mechanical treatment (such as ultrasonic welding, compression, and the like), or a combination thereof.

In an embodiment of the invention, at least a portion of the periphery of the sheet material may be sealed. In an alternative embodiment of the invention, substantially all of the periphery of the sheet material may be sealed. In an embodiment of the invention, at least a portion of the periphery of the sheet material may be sealed prior to assembling the sheet material into an outer box layer and/or a lid. In an embodiment of the invention, at least a portion of the periphery of the outer box layer and/or the lid may be sealed after assembly from a sheet material.

In an embodiment of the invention, the outer box layer and/or the lid may be fabricated from a water resistant thermal insulation sheet material. In a further embodiment of the invention, the outer box layer and/or the lid may be fabricated from a water resistant thermal insulation sheet material, wherein overlapping or abutting side edges of the sheet material may be sealed with an adhesive, water-proof tape. In this instance, it is envisaged that sealing abutting side edges of the outer box layer and/or the lid with a water-proof tape may improve the water-resistance of the outer box layer and/or the lid. Preferably, the water-resistant thermal insulation sheet material may have sealed edges. In this way, the thermal insulating capacity of the material is improved and the sheet material has improved water-resistance.

The water-resistant thermal insulation sheet material may comprise at least one layer. In an embodiment of the invention, the water-resistant thermal insulation sheet material may be a multi-layer structure. In a preferred embodiment, the water resistant thermal insulation sheet material may be a twin wall plastic structure. Preferably, the water-resistant thermal insulation sheet material may be a corrugated plastic. In an embodiment of the invention, the water-resistant thermal insulation sheet material comprises a plastic corrugated twin wall sheet consisting of two flat sheets connected by parallel ribs. In some embodiments of the invention, the water-resistant thermal insulation sheet material may be fabricated from polyethylene, polypropylene, polyvinyl chloride, polyethylene terephthalate, polycarbonate, acrylonitrile butadiene styrene or the like, or any suitable combination thereof.

Suitable commercially available water-resistant thermal insulation sheet materials include Corflute® sheets manufactured by Corex Plastics (Australia) Pty. Ltd.

In an embodiment of the invention, the outer box layer and/or the lid may be at least UV resistant. Any suitable means of providing the outer box layer and/or the lid with UV-resistance may be used. For instance, the outer box layer and/or the lid may be formed of a substantially UV-resistant thermal insulation sheet material, may be provided with a UV resistant coating, or combinations thereof. In an embodiment of the invention, the outer box layer and/or the lid may be provided with a coating in the form of a UV resistant film, such as a metallised plastic film. In a preferred embodiment of the invention, the outer box layer and/or the lid may be provided with a metallised polypropylene film. Preferably, the outer box layer and/or the lid may be provided with a metallised oriented polypropylene film. It is envisaged that in use, the metallised plastic film may improve the thermal performance of the outer box layer and/or the lid when exposed to sunshine.

The outer box layer and/or the lid may be formed in any manner known in the art, e.g. by folding a blank or stamped sheet material along preformed lines to raise side and end panels from a base panel. One or more sheets of material may be used. In an embodiment of the invention, a top wall integrally formed as part of the outer box layer blank may be folded over to form a lid. In this instance, it is envisaged that the top wall may be an extension to one or more side walls of the outer box layer blank. Alternatively, a lid in the form of an open box structure may be formed from a blank. In this instance, it is envisaged that the lid may be fitted over the outer box layer such that the side panels of the lid extend at least partially over the side panels of the outer box layer. In a further embodiment of the invention, a sheet of material may be attached to an upper rim of the outer box layer to form a lid or closure.

One of more side walls of the outer box layer and/or the lid may be attached to an adjacent side wall by any suitable technique. For instance, the overlapping or abutting side edges of the sheet material may be fastened using an adhesive, an adhesive tape, an aluminium foil tape, or a mechanical fastener (such as stitching, staples), or any suitable combinations thereof. Alternatively, the edges of the sheet material may be fastened together by inserting one or more locking tabs located on the edge of a sheet material at least partially into one or more tab-retaining slots located on an opposing edge of a sheet material. Alternatively, the edges of the sheet material may be fastened together by folding over one or more locking flaps located on an edge of a first portion of the sheet material such that the one or more folded locking flaps may at least partially extend across an edge of an adjacent portion of the sheet material. It is envisaged, that in use, more than one technique for fastening the edges of a sheet material may be used. In an embodiment of the invention, overlapping or abutting side edges of the sheet material may be sealed with an adhesive water-proof tape. In this instance, it is envisaged that sealing abutting side edges of the inner lining with a water-proof tape may improve the water-resistance of the inner lining.

The outer box layer and/or the lid may be provided with one or more straps. The straps may be any suitable size, shape, and configuration. Preferably, however the straps are of sufficient size and mechanical properties (strength, rigidity, shape, etc.) to move and lift the thermal insulating transport container. In use, it is envisaged, that the one or more straps may also secure a lid to the outer box layer.

In an embodiment of the invention, the thermal insulating transport container further comprises a cardboard outer container. In an alternative embodiment of the invention, the thermal insulating transport container further comprises a cardboard sleeve. Any suitable cardboard outer container or cardboard sleeve may be used. It is envisaged that in use the company brand, sender details, recipient details, information pertaining to the perishable goods, or the like may be printed on the cardboard outer container or cardboard sleeve. In this way, the thermal insulating transport container may be reused by different companies.

The thermal insulating transport container may be provided with one or more monitoring devices. The monitoring device may be of any suitable type, and may monitor any suitable parameter associated with the thermal insulating transport container. Preferably, however, the one or more monitoring devices provide information regarding the condition of the inner lining and/or the outer box layer and/or the lid. For instance, a suitable monitoring device may be an electronic monitoring device. The electronic monitoring device may include an electronic chip, an Internet of Things (IoT) module, a data logger, radio frequency identification (RFID) chip, near field communication (NFC) tag, smart tag, or the like. It is envisaged that in use, the monitoring device may be used to track and/or trace the thermal insulating transport container or its individual components, identify worn or damaged components, monitor temperature or humidity at one or more locations within the thermal insulating transport container, or combinations thereof. In an embodiment of the invention, one or more of the inner lining, the outer box layer and the lid may be provided with one or more monitoring devices.

For example, tracking and verification of reusability and recyclability of the thermal insulating transport container may be accomplished by embedding an electronic chip (IoT) at the point of manufacture within each of the individual components of the container. Each layer may be scanned at point of manufacture (and one or more other points of the product lifecycle, such as by the sender, the transporter, the receiver, the recycler etc.) via an electronic chip reading device and the data from each embedded electronic chip may be transmitted to a receiver, such as the cloud and the API of a Blockchain platform. Thus, the data may be written to a Blockchain. Advantageously, this allows the location of the thermal insulating transport container to be traced through its entire life cycle (e.g. from first use to recycling). It is envisaged that this may deliver full validation on reuse and recyclability. Additionally, this information may be used to assist in stock replenishment.

The one or more monitoring devices may be located in any suitable portion of the inner lining, the outer box layer and the lid. However, it will be understood that the location of the monitoring device may vary depending on a number of factors, such as the function of the monitoring device and the frequency of transmission (both in terms of the frequency in time with which the monitoring device transmits and/or the radio frequency on which the monitoring device transmits). In an embodiment of the invention, the monitoring device may be located on a surface of the inner lining and/or the outer box layer and/or the lid. In this instance, it is envisaged that the monitoring device may be at least partially covered by a polymer film, to provide the monitoring device with a protective barrier and to secure the monitoring device to the inner lining and/or the outer box layer and/or the lid. In an embodiment of the invention, the monitoring device may be located within the structure of the inner lining and/or the outer box layer and/or the lid.

The inventors have found that the combination of an inner lining, a water resistant outer box layer and a lid as described above provides an alternative to polystyrene as an “out of cold chain” transport container.

The present invention provides a number of advantages over the prior art. For instance, the present invention provides improved thermal insulation which makes it an effective transport container suited for “out of cold chain” product transport. In addition, the present invention improves flexibility in use through customisable construction and ability to collapse (flat-packed) for convenient “cost effective transport” and convenient storage when not in use. The present invention also improves cost efficiency and sustainability through the ability to reuse and recycle without breakdown of the material. In addition, the present invention does not require additional moisture/leakage barriers in the form of single-use plastic liner bags which improves the ability of the transport container to be fully recyclable.

In another aspect, the invention resides broadly in a thermal insulating transport container comprising:

-   -   an inner thermal insulation sheet layer; and     -   a water resistant outer thermal insulation box layer,         wherein a side wall of the outer box layer is connected to an         adjacent side wall of the outer box layer by at least one         locking tab.

In another aspect, the invention resides broadly in a method of manufacture of a thermal insulating container, comprising the steps:

-   -   a. obtaining an inner thermal insulation sheet layer;     -   b. creasing the inner thermal insulation sheet layer and folding         along the formed crease to form at least one edge in the inner         thermal insulation sheet layer to a required size;     -   c. creasing the outer thermal insulation sheet layer and folding         along the formed crease to form at least one side wall in the         outer thermal insulation sheet layer to a required size;     -   d. placing the folded inner thermal insulation sheet layer from         step b inside the folded outer thermal insulation sheet layer         from step c; and     -   e. connecting at least one locking tab positioned on a side wall         of the outer thermal insulation box layer to an adjacent side         wall of the outer thermal insulation box layer.

Any of the features described herein can be combined in any combination with any one or more of the other features described herein within the scope of the present invention.

The reference to any prior art in this specification is not, and should not be taken as an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge.

BRIEF DESCRIPTION OF DRAWINGS

Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows:

FIG. 1 illustrates a perspective view of a thermal insulating container according to an embodiment of the invention without lid;

FIG. 2 illustrates a perspective view of an inner lining according to an embodiment of the invention;

FIG. 3 illustrates an inner lining according to an embodiment of the invention in a storage condition;

FIG. 4 illustrates a perspective view of a thermal insulating container according to an embodiment of the invention where the inner lining has not been sealed;

FIG. 5 illustrates a front view of a thermal insulating container according to an embodiment of the invention where the inner lining has not been sealed;

FIG. 6 illustrates a blank used to form an outer box layer according to an embodiment of the present invention;

FIG. 7 illustrates a blank used to form a lid for an outer box layer according to an embodiment of the present invention;

FIG. 8 illustrates a blank used to form an inner lining according to an embodiment of the present invention;

FIG. 9 illustrates a blank used to form an inner lining according to an embodiment of the present invention;

FIG. 10 illustrates a perspective view of an outer box layer according to an embodiment of the invention;

FIG. 11 illustrates a top view of a lid for an outer box layer according to an embodiment of the invention and shown in an inverted condition;

FIG. 12 shows a close up view of the side edges of an inner lining according to an embodiment of the invention;

FIG. 13 shows a front view of a lid according to an embodiment of the invention;

FIG. 14 shows a graph of temperature changes for an airfreight approved, expanded polystyrene box and the thermal insulating transport container according to an embodiment of the present invention;

FIG. 15 shows a graph of temperature changes for an airfreight approved, expanded polystyrene box and the thermal insulating transport container according to an embodiment of the present invention;

FIG. 16 shows a top perspective view of a thermal insulating transport container according to an embodiment of the invention without lid;

FIG. 17 shows a top perspective view of an inner lining according to an embodiment of the invention;

FIG. 18 shows a perspective view of a thermal insulating transport container according to an embodiment of the invention;

FIG. 19 illustrates a thermal insulating transport container according to an embodiment of the invention in use;

FIG. 20 illustrates a thermal insulating transport container according to an embodiment of the invention;

FIG. 21 illustrates a thermal insulating transport container according to an embodiment of the invention in use;

FIG. 22 illustrates a thermal insulating transport container according to an embodiment of the invention in use;

FIG. 23 shows a graph of temperature and humidity over 1.2 day time period during transport testing of an airfreight approved corrugated cardboard container;

FIG. 24 shows a graph of temperature and humidity over 1.2 day time period during transport testing of a transport container manufactured from plastic corrugated twin wall sheets; and

FIG. 25 shows a graph of temperature and humidity over 1.2 day time period during transport testing of a thermal insulating transport container according to an embodiment of the invention.

DESCRIPTION OF EMBODIMENTS

In FIG. 1, a thermal insulating transport container (100) according to an embodiment of the invention is illustrated. The thermal insulating transport container (100) comprises an inner lining (1) and an outer box layer (2). A lid (not shown) for the outer box layer (3) may be provided. Outer box layer (2) may comprise one or more apertures (10 a, 11 a, 13 a) which substantially align with monitoring devices (10, 11, 13) located on the inner lining (1). Apertures (10 a, 11 a, 13 a) may be at least partially covered by a polymer film, to provide the device with a protective barrier and to maintain the water resistance of the outer box layer (2). Outer box layer (2) may comprise one or more monitoring devices (9), such as a NFC tag, which may track the location of the outer box layer or passively monitor and log the temperature. A side wall of the outer box layer (2) may be connected to an adjacent end wall by at least one male locking tab (4) which fits into a corresponding female locking pocket (not shown).

In FIG. 2, the inner lining (1) of a thermal insulating transport container (100) according to an embodiment of the invention is illustrated. In FIG. 3, the inner lining (1) of a thermal insulating transport container according to an embodiment of the invention is illustrated in a storage condition. In FIG. 4, a thermal insulating transport container (100) according to an embodiment of the invention is illustrated in use wherein inner lining (1) in a partially assembled state is substantially received in outer box layer (2).

In FIGS. 2 to 4, inner lining (1) comprises an outer facing fabricated from a metallised reflective layer and an inner facing fabricated from a food grade antimicrobial layer. An NFC tag (13) is located on the outer facing of the inner lining (1). In a fully assembled state, it is envisaged that an end of the inner lining (1) may be folded over on a thermally induced fold lines (17) in the inner lining (1) and sealed by compression (18) to close the inner lining (1). (Tape (12) to hold inner lining closed is used for display purposes only. Weights (25) to hold the inner lining flat are used for display purposes only.)

In FIG. 5, a thermal insulating transport container (100) according to an embodiment of the invention is illustrated in use wherein inner lining (1) in a partially assembled state is partially received in outer box layer (2). In an assembled state, side locking flaps (7) on a side wall of the outer box layer (2) are folded over such that they extend at least partially across side locking tabs (6) and into the cavity of the outer box layer (2). In this way, it is envisaged that the side locking flaps (7) substantially retain the end wall and side wall of outer box layer (2) in an erected condition. In an assembled state, male locking tabs (4) which fit into corresponding female locking pockets (5) when the outer box layer (2) and substantially retain the end wall and the side wall of the outer box layer (2) in an erected condition.

In FIG. 6, a blank for forming an outer box layer (2) according to an embodiment of the invention is illustrated. The outer box layer (2) comprises male locking tabs (4) which fit into corresponding female locking pockets (5) and side locking flaps (7) which fit into corresponding locking pockets (6) on an end wall of the outer box layer.

In FIG. 7, a blank for forming a lid (3) for an outer box layer (2) according to an embodiment of the invention is illustrated. Lid (3) comprises end locking tabs (19) located on the edge of the end walls and side walls of the lid (3) and end locking flaps (20) hingedly attached at each end wall of lid (3). Lid (3) further comprises male locking tabs (21) which, fit into corresponding female locking pockets (22). Indica (200) may be provided on an outer surface of the lid (3).

In FIGS. 8 and 9, a blank for forming an inner lining (1) according to an embodiment of the invention is illustrated. The inner lining (1) comprises thermally induced formed fold lines (17) and one or more monitoring devices (13,11), such as NFC tags, which may track the location of the outer box layer or passively monitor and log the temperature. At least a portion of inner lining (1) comprises sealed edges (23). Inner lining (1) comprises an outer facing fabricated from a metallised reflective layer, the periphery of which extends beyond the periphery of an inner facing at (overlapping material, 24). It is envisaged that when the inner lining is assembled, overlapping material (24) on one portion of the inner lining (1) may abut overlapping material (24) on second portion of the inner lining (1). The abutting, overlapping material (24) may be sealed to provide a water-resistant barrier.

In FIG. 10, lid (3) in the form of an open box structure may be fitted over the outer box layer (2) such that the side panels of the lid extend substantially over the side panels of the outer box layer (2). Lid (3) comprises male locking tabs (21) which fit into corresponding female locking pockets (22). Lid (3) may be provided with one or more monitoring devices (8) which may track the location of the outer box layer or passively monitor and log the temperature. Lid (3) may also be provided with apertures (16) which substantially align with monitoring devices (10, 11 and 13) located on the inner lining (1). Apertures (16) may be at least partially covered by a polymer film, to provide the device with a protective barrier and to maintain the water resistance of the lid (3). Lid (3) may comprise one or more monitoring devices (8), such as an NFC tag, which may track the location of the outer box layer or passively monitor and log the temperature.

In FIG. 11, a top view of a lid for an outer box layer in an inverted condition is shown. Locking flaps (20) on an end wall of the lid (3) are folded over such that the folded locking flaps at least partially extend across locking tabs (19) located on adjacent end and side walls of lid (3) and into the cavity of the lid (3). In this way, it is envisaged that the end locking flaps (20) substantially retain the end and side walls of the lid (3) in an erected condition. In an assembled state, the lid (3) comprises male locking tabs (21) which fit into corresponding female locking pockets (22) substantially retain the end wall and side wall of lid (3) in an erected condition.

In FIG. 12, a close up view of the side edges of an inner lining (1) according to an embodiment of the invention are shown. Inner lining (1) comprises thermally induced fold lines (17) and sealed edges (23).

In FIG. 13, a front view of a lid (3) according to an embodiment of the invention is illustrated. Lid (3) is provided with a metallised oriented polypropylene film (29) for improved thermal performance. The metallised oriented polypropylene film (29) may be provided with apertures (16) which substantially align with monitoring devices (10, 11 and 13) located on the outer box layer and/or the inner lining (not shown). Apertures (16) may be at least partially covered by a polymer film, to provide the device with a protective barrier and to maintain the water resistance of the lid (3). The lid (3) may comprise one or more monitoring devices (8), such as an NFC tag, which may track the location of the lid or passively monitor and log the temperature.

In FIG. 14, the results of a trial assessing the internal temperature changes of an airfreight approved, expanded polystyrene box and the thermal insulating transport container of the present invention is shown (see Example 2). Surprisingly, the thermal insulating transport container of the present invention has a higher thermal resistance than an expanded polystyrene box, exhibiting a slower increase in temperature than the current airfreight approved expanded polystyrene box.

In FIG. 15, a graph of temperature changes for an airfreight approved, expanded polystyrene box and embodiments of the thermal insulating transport container of the present invention is shown (see Example 3). Surprisingly, the thermal insulating transport container of the present invention has a higher thermal resistance than an expanded polystyrene box, exhibiting a slower increase in temperature than the current airfreight approved expanded polystyrene box. The experiment also demonstrates that providing the thermal insulating transport container with an additional reflective layer on an outside surface of the lid (Box 1 and Box 2, Silver KoolPak, versus Box 3, White KoolPak) improves the thermal performance of the thermal insulating transport container.

In FIG. 16, a thermal insulating transport container (300) according to an embodiment of the invention is illustrated. Thermal insulating transport container (300) comprises an inner lining (301) and an outer box layer (302). Outer box layer (302) and inner lining (301) are shown in a substantially rectangular prism configuration which may be used for the transportation of whole fish.

In FIG. 17, the inner lining (301) of the thermal insulating transport container (300) is shown in a partially assembled state. Inner lining (301) is fabricated from a thermal insulation sheet layer comprising a foam layer encapsulated between an upper and lower reflective layer. Edges (305) of the inner lining have been sealed to improve the thermal insulating capacity of the material and to assist with food grade status approval. In use, it is envisaged that side walls (303) of the inner lining may be formed by bending a flexible sheet of material along preformed lines (306) and longitudinally closing the ends (304) using an aluminium tape (307).

In FIG. 18, the outer box layer (302) of the thermal insulating transport container (300) is shown. Outer box layer (302) is fabricated from a water-resistant thermal insulation sheet layer in the form a pair of sheets separated by a plurality of ribs. The outer box layer may have sealed edges (not shown) to improve the thermal insulating capacity of the material and assist with food grade status approval. In use, it is envisaged that the outer box layer (302) may be formed by folding a box blank along preformed lines to form a base (not shown), side walls (313) and end walls (314). A side wall (313) may be connected to an adjacent end wall (314) by at least one male locking tab (318) which fits into a corresponding female locking pocket (not shown). A lid (319) may be formed by bending a side wall (313) along a preformed line and securing abutting edges of side wall (313) and lid (319) with adhesive tape.

In FIGS. 19 and 20 a thermal insulating transport container (300) in a cardboard box (320) is shown. Optionally, straps (321) may be provided to secure lid (319) to outer box layer (302). In use, it is envisaged, that straps (321) may assist in moving and lifting the thermal insulating transport container (300).

In FIG. 21, a thermal insulating transport container according to an embodiment of the invention is shown in use. The inner lining (1) comprising an inner facing fabricated from a food grade antimicrobial layer (26) has been packed with fresh fish fillets (28) and frozen gel packs (27). FIG. 21 in an empty state is the container used in a transport trial (Example 3, Box 2 Silver KoolPak).

In FIG. 22, a thermal insulating transport container according to an embodiment of the invention used in a transport trial (see Example 1) is shown. The inner lining (301) comprising an inner facing fabricated from a reflective layer and sealed with aluminium tape (307) has been packed with fish fillets (28) inside a plastic bag.

FIGS. 23 to 25 illustrate the change in temperature and humidity over 1.2 day time period during transport testing of an airfreight approved, corrugated cardboard container (FIG. 23), a transport container fabricated from plastic corrugated twin wall sheets (FIG. 24) and a thermal insulating transport container according to an embodiment of the invention (FIG. 25) as explained in Example 1. Surprisingly, the thermal insulating transport container of the present invention is more effective at maintaining a stable humidity and temperature than the current airfreight approved packaging options.

EXAMPLE 1: TEMPERATURE AND HUMIDITY MONITORING USING DIFFERENT TRANSPORT CONTAINERS

A data logger was placed in with the whole fish inside a 100 micron polyethylene bag and goose neck cable tied closed. This package resided inside a second 100 micron polyethylene bag that contained the cooling gel packs, it was also goose neck cable tied closed (maintaining separation of fish and gel packs). Both fish and gel packs resided inside the thermal lining which was fitted inside the test transport containers (see FIG. 22). The test transport containers included an airfreight approved, corrugated cardboard container, a transport container fabricated from plastic corrugated twin wall sheets (“Fluted PP transport container”) and the thermal insulating transport container of the present invention. The Fluted PP transport container and the thermal insulating container of the present invention were placed inside an airfreight approved, corrugated cardboard container for transport in order to comply with the appropriate regulations.

The humidity and temperature of the interior of each box was monitored over a time period of 1.2 days every 15 minutes.

The results for the airfreight approved, corrugated cardboard container may be found in FIG. 23.

The humidity and temperature in the cardboard container varied considerably. The temperature varies between 18.6° C. and 2.5° C. with an average of 6.9° C. and represented an “out of cold chain” transport situation 3 times for varying duration. Temperature and humidity stabilised only after re-entry in the cold chain at time point approximately 20:53.

This clearly shows that the airfreight approved, corrugated cardboard container is not efficient at maintaining the required temperature and humidity to ensure the quality of the product and therefore not suitable as a standalone “out of cold chain” transport container.

The results for the Fluted PP transport container may be found in FIG. 24.

Both the humidity and temperature varied although the insulation qualities of the Fluted PP transport container reduced that somewhat. The temperature varies between 15.9° C. and 3.2° C. with an average of 3.6° C. The humidity varies between 85.2% to 68.9% with an average of 82.1%. Temperature and humidity stabilised only after re-entry in the cold chain at time point approximately 20:53.

This clearly shows that a transport container fabricated from plastic corrugated twin wall sheets is not efficient at maintaining the required temperature and humidity to ensure the quality of the product and therefore not suitable as a standalone “out of cold chain” transport container.

The results for the thermal insulating transport container of the present invention may be found in FIG. 25.

Both the humidity and temperature are relatively constant and only varied during activation and placement in the consignment. The temperature varies between 15.1° C. and −0.6° C. with an average of 0.2° C. But once stabilised at time point approximately 06:08 the variation is negligible. The humidity varied between 93.1% to 68.2% with an average of 90.6%. But once stabilised at time point approximately 06:08 the variation is negligible.

This shows that the thermal insulating transport container of the present invention is efficient at maintaining the required temperature and humidity to ensure the quality of the product.

EXAMPLE 2: MEASURING THE THERMAL RESISTANCE OF AN EXPANDED POLYSTYRENE BOX AND A THERMAL INSULATING TRANSPORT CONTAINER OF THE PRESENT INVENTION

An airfreight approved, expanded polystyrene box and the thermal insulating transport container of the present invention were provided with data loggers and sealed. The boxes were placed in an environment having a temperature of 4° C. and when equilibrated were transferred to a second environment having a temperature of 30° C. The temperature of the interior of the empty boxes was monitored over a time period of approximately 90 minutes at one minute intervals. The results are shown in FIG. 14.

The internal temperature of the polystyrene box reached 25° C. after 30 minutes and 30° C. after approximately 65 minutes. In contrast, the container of the present invention required approximately 43 and 83 minutes respectively to reach the same temperatures.

This result clearly shows that the container of the present invention has a higher thermal resistance than an expanded polystyrene box.

EXAMPLE 3: MEASURING THE THERMAL RESISTANCE OF DIFFERENT TRANSPORT CONTAINERS

An airfreight approved, expanded polystyrene box and the thermal insulating transport container of the present invention were provided with data loggers and sealed. Two of the thermal insulating transport containers were provided with a metallised oriented polypropylene film on the outside surfaces of the lid.

The boxes were placed in an environment having a temperature of 4° C. and when equilibrated were transferred outdoors having an environmental temperature of 33° C. and exposed to sunlight. The temperature of the interior of the empty boxes was monitored over a time period of approximately 90 minutes at one minute intervals. The results are shown in FIG. 15.

The internal temperature of the polystyrene box reached 25° C. after 20 minutes and exceeded the environmental temperature (33° C.) after approximately 25 minutes. The transport container of the present invention (without metallised oriented polypropylene film) required approximately 30 and 40 minutes respectively to reach the same temperatures. The transport container of the present invention (with metallised oriented polypropylene film) required approximately 30 and 50 minutes respectively to reach the same temperatures.

This result clearly shows that the container of the present invention has a higher thermal resistance than polystyrene. This result also shows that providing the transport container of the present invention with an additional reflective layer on the outside of the lid improves the thermal performance of the transport container when exposed to sunlight.

In the present specification and claims (if any), the word ‘comprising’ and its derivatives including ‘comprises’ and ‘comprise’ include each of the stated integers but does not exclude the inclusion of one or more further integers.

Reference throughout this specification to ‘one embodiment’ or ‘an embodiment’ means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases ‘in one embodiment’ or ‘in an embodiment’ in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims (if any) appropriately interpreted by those skilled in the art. 

1. A thermal insulating transport container for the transportation of perishable goods, the thermal insulating transport container comprising: an inner lining comprising one or more side walls formed by bending a sheet material along preformed lines, wherein the inner lining is fabricated from a thermal insulation sheet material; and an outer box layer, wherein the outer box layer is fabricated from a water resistant thermal insulation sheet material and wherein when assembled, the outer box layer is substantially waterproof, wherein a side wall of the outer box layer is connected to an adjacent side wall of the outer box layer by at least one locking tab, wherein the inner lining is adapted to be substantially received and retained within the outer box layer, and wherein the thermal insulation sheet material and/or the water resistant thermal insulation sheet material have sealed edges.
 2. The thermal insulating transport container as claimed in claim 1, further comprising a lid, wherein the lid is fabricated from a water resistant thermal insulation sheet material.
 3. The thermal insulating transport container as claimed in claim 1, wherein the inner lining is fabricated from a material comprising two or more layers.
 4. The thermal insulating transport container as claimed in claim 3, wherein one or more of the layers is a foam layer.
 5. The thermal insulating transport container as claimed in claim 3, wherein one or more of the layers is a closed cell foam layer.
 6. The thermal insulating transport container as claimed in claim 4, wherein the foam layer is encapsulated between two or more layers of a reflective material.
 7. The thermal insulating transport container as claimed in claim 4, wherein the foam layer is encapsulated between two or more layers of an antimicrobial material.
 8. The thermal insulating transport container as claimed in claim 4, wherein the foam layer is encapsulated between one or more layers of a reflective material and one or more layers of an antimicrobial material.
 9. The thermal insulating transport container as claimed in claim 7, wherein the antimicrobial material is a food grade antimicrobial material.
 10. The thermal insulating transport container as claimed in claim 1, wherein the inner lining is fabricated from a flexible, thermal insulation sheet material.
 11. The thermal insulating transport container as claimed in claim 1, wherein the inner lining is fabricated from a water-resistant thermal insulation sheet material.
 12. The thermal insulating transport container as claimed in claim 1, wherein the outer box layer is fabricated from a material comprising two or more layers.
 13. The thermal insulating transport container as claimed in claim 1, wherein the outer box layer is fabricated from a corrugated twin wall plastic sheet.
 14. The thermal insulating transport container as claimed in claim 1, wherein at least one of the inner lining, the outer box layer, or the lid, comprise one or more monitoring devices.
 15. The thermal insulating transport container as claimed in claim 14, wherein at least one monitoring device is used to track the location of the thermal insulating transport container, the inner lining thereof, the outer box layer thereof, or the lid thereof.
 16. The thermal insulating transport container as claimed in claim 14, wherein data obtained from the one or more monitoring devices is written to a Blockchain. 